Box Blank Feeder for Narrow Spacing

ABSTRACT

A feeder device for supplying a container blank to an apparatus is provided. The feeder device includes a loader adapted to supply at least one blank and a singulation mechanism. The singulation mechanism is operatively positioned relative to the loader for separating the at least one blank from the loader. The feeder device also includes a transport mechanism in communication with the singulation mechanism and is adapted to supply the at least one blank to the apparatus. A motion control assembly is in communication with the singulation mechanism to selectively adjust positioning of the singulation mechanism between the loader and the transport mechanism.

BACKGROUND

Water resistant shipping containers are desirable for shipping many types of products, such as fresh produce and frozen goods. Currently available containers are typically manufactured from container blanks that are encapsulated within a water resistant film. Such blanks are assembled by applying a film to both sides of the blank and trimming to size. The covered blank is then heated above the softening point of the film. The film becomes bonded to the surfaces of the blanks, and sags around the edges and into any openings so that the film on the two sides of the blank come into contact and are sealed together.

Thereafter, the edges and any slits and cutouts are trimmed, such as by a die cutter, white preserving the seals along the edges. One such method of manufacturing an encapsulated blank is disclosed in U.S. Pat. No. 6,338,234, entitled Method of Encapsulating Shipping Container Blanks in Plastic Film, assigned to Weyerhaeuser Company of Federal Way, Wash., the disclosure of which is hereby expressly incorporated by reference.

While current manufacturing methods are effective at encapsulating blanks, they are not without their problems. As a nonlimiting example, currently available manufacturing methods are manually fed the container blanks. This results in inefficient spacing between succeeding blanks durin g the encapsulation process. This also results in wasted material as the material located in the spacing between container blanks is unused. Further, beause such machinery is manually fed container blanks, this results in increased manufacturing costs. Thus, there exists a need for a feeder device.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

A feeder device for supplying a container blank to an apparatus is provided. The feeder device includes a loader adapted to supply at least one blank and a singulation mechanism. The singulation mechanism is operatively positioned relative to the loader for separating the at least one blank from the loader. The feeder device also includes a transport mechanism in communication with the singulation mechanism and is adapted to supply the at least one blank to the apparatus. A motion control assembly is in communication with the singulation mechanism to selectively adjust positioning of the singulation mechanism between the loader and the transport mechanism.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is an isometric view of a feeder device constructed in accordance with one embodiment of the present invention with certain aspects of the feeder device removed for clarity;

FIG. 2 is a schematic representation of the feeder device of FIG. 1; and

FIG. 3 is a partial schematic view of the feeder device of FIG. 2, showing operational aspects of a singulation device constructed in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

A feeder device 20, constructed in accordance with one embodiment of the present disclosure, may be best understood by referring to FIGS. 1 and 2. The feeder device 20 is illustrated for use in conjunction with a well-known container blank encapsulation apparatus 22. The container blank encapsulation apparatus 22 includes a pair of opposed first and second rollers 24 a and 24 b and first and second adhesive applicators 26 a and 26 b.

The applicators 26 a and 26 b are positioned to apply a hot melt adhesive to first and second film layers 28 a and 28 b before the film layers 28 a and 28 b are applied to a container blank 30. Such container blanks 30 are suitably formed from well-known cellulose materials, such as wood pulp, straw, cotton, bagasse and the like. The container blanks 30 are sequentially fed into the encapsulation apparatus 22 where they are encapsulated within the film layers 28 a and 28 b.

The feeder device 20 includes a loader 40, a singulation mechanism 42, a transport mechanism 44, and a motion control assembly 46. The loader 40 is a well-known device adapted to permit a continuous feed of container blanks 30. It is envisioned that such a loader 40 provides a continuous supply of stacked container blanks to the singulation mechanism 42. Thus, any suitable available loader that provides a continuous supply of container blanks is within the scope of the disclosure.

As may be best seen by referring to FIG. 1, the singulation mechanism 42 includes first and second gripping assemblies 50 a and 50 b. The gripping assemblies 50 a and 50 b extend parallel to each other in a longitudinal direction and are off-set from each in a width direction. As constructed, the first and second gripping assemblies 50 a and 50 b are both adjacent and staggered from each other.

Although only two gripping assemblies 50 a and 50 b are illustrated and described, it should be apparent that singulation mechanisms 42 having more or less gripping assemblies are also within the scope of the present disclosure. Specifically, operation efficiencies may dictate the design of the singulation mechanism and, therefore, such mechanisms may include one, two, three, four, etc., gripping assemblies. As such, the disclosed embodiments should not be construed as limited by the illustrated embodiment.

As the first and second gripping assemblies 50 a and 50 b are identically configured, only one gripping assembly will be described in greater detail. However, it should be apparent that the description of one applies to the other. One suitable embodiment of a gripping assembly 50 within the scope of the present disclosure includes a drive motor 52, first and second drive axles 54 a and 54 b, at least one conveyor 56, and at least one gripping device 58.

The drive motor 52 is suitably a well-known servo-motor operatively connected to one of either the first or second drive axles 54 a and 54 b in any manner known to one of ordinary skill in the art. The conveyor 56 is suitably a belt that extends between the first and second drive axles 54 a and 54 b. The drive motor 52 is in communication with a well-known motion controller 60 to selectively reciprocate the gripping device 58 along a desired velocity profile, as described in greater detail below with respect to FIG. 3.

The gripping device 58 is suitably vacuum operated and includes a piston 70 having one end (not shown) slidably disposed within a cylinder 72. The other end of the piston 70 includes a gripping head 74, such as a suction cup. The gripping head 74 is in fluid communication with a vacuum source (not shown) by a valve assembly 76 extending from the cylinder 72. The gripping device 58 is suitably fastened to the conveyor 56 in any manner known to one of ordinary skill in the art. While gripping assembly 50 of the presently described embodiment includes only one gripping device 58, it should be apparent that gripping assemblies with more gripping devices, such as two, three, four, etc., are also within the scope of the appended claims.

Although a vacuum operated gripping device is illustrated and described, the present disclosure is not intended to be so limiting. As non-limiting examples, pneumatic and robotic gripping devices are also contemplated within the scope of the present disclosure. Accordingly, the disclosure of vacuum operated gripping devices should be construed as exemplary and the scope of the gripping device includes pneumatic, mechanical, and vacuum operated devices.

Still referring to FIGS. 1 and 2, the transport mechanism 44 will now be described in greater detail. The transport mechanism 44 includes at least one belt 80 and a drive motor 82 operatively connected to one or more drive axles 84 to drive the belt 80 any given web speed. The transport mechanism 80 is connected to a vacuum source (not shown) to assist in securing container blanks 30 as they pass through the feeder device 20. In such embodiments, the belt 80 includes a plurality of holes (not shown) extending through the belt to provide suction points along its length. As a vacuum is applied to the transport mechanism 44, negative air pressure draws air through the holes to assist in holding the container blank 30 downwardly against the belt 80 as it is transported to the encapsulation apparatus 22.

As seen best in FIG. 1, the transport mechanism 44 includes a plurality of belt 80 across its width. While such a configuration is desirable, other configuration having more or fewer belts 80 are also within the scope of the present disclosure. Further, it should be apparent that the transport mechanism 44 need not be a vacuum operated device. As an example, the transport mechanism may include belts that include a gritted surface to help restrain the container blank during transport. As such, the scope of the transport mechanism should be construed broadly to include such examples and their structural equivalents.

Operation of the feeder device 20 may be best understood by referring to FIG. 3. Upon activation of the feeder device 20, the loader 40 provides a continuous supply of container blanks 30 the singulation mechanism 42. The motion controller 60 has prepositioned the gripping device 58 at a starting location near the loader 40. The piston 70 of the gripping device 58 is extended into a pick-up position A, such that the gripping head 74 is placed into contact with the container blank 30.

As the gripping device 58 includes a vacuum, it applies a suitable restraining pressure sufficient to releasably attach the container blank 30 to the gripping head 74. Recall that the described embodiment includes a plurality of gripping devices displaced along the width of the container blank 30. As such, each gripping device does not necessarily singularly apply a vacuum pressure sufficient to pick-up the container blank 30. The exact vacuum required to pick-up a container blank is function of the size and weight of the container blank as well as the open area of the gripping device and the calculation of such vacuum is within the skill of an ordinary person in the art.

After the gripping device 58 restrains the container blank 30, well-known controls retract the piston 70 into a transport position B sufficient to lift the container blank 30 from the stack and clear surrounding obstacles. The motion controller 60 signals the motor 52 to accelerate the conveyor 56 to move the container blank 30 towards a transport surface 90 where the container blank 30 is guided towards opposed nips 92 a and 92 b. The nips 92 a and 92 b are located adjacent the transport mechanism 44 and provide additional positioning restraint capabilities to assist in maintaining positioning of the container blank 30 as it is being transported towards the encapsulation apparatus 22. After the container blank 30 is captured by the opposed nips 92 a and 92 b, well-known controls retract the piston into release position C, the vacuum is released and the gripping device 58 is returned to the starting location.

As briefly noted above, the motion controller 60 allows an operator to program the velocity profile of the singulation mechanism 42. Specifically, the velocity profile can be programmed in any desired mainer. As an example, the controller 60 may increase the velocity of the conveyor 56 to propel the gripping device 58 connected to the container blank 30 to a speed greater than the web speed. As the container blank 30 approaches the transport surface 90 and the nips 92 a and 92 b, the controller 60 may slow the conveyor 56 to the web speed.

By properly programming the acceleration and deceleration of the conveyor 56, the leading edge of the container blank 30 gripped by device 58 will approach the trailing edge of the previous container blank. As a result, the gap between the leading and trialing edges of all blanks of the same size can be made substantially consistent. This ensures consistent spacing 100 (FIG. 2) between successive container blanks 30. In one embodiment, the spacing 100 is approximately 0.5 inch. After the gripping device 58 releases the container blank 30, the gripping device 58 is retracted into the release position and is accelerated back to the starting position where the process may be repeated.

Thus, the velocity profile may be programmed to any desired profile of the operator's choosing. This permits the operator to control the spacing between successive container blanks 30 as they are feed into the encapsulation apparatus 22. Again, it should be apparent that the velocity profile at which the singulation mechanism 42 operates may be programmed as desired, including a substantially constant profile having a speed substantially equal to the web speed.

While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. 

1. A feeder device for supplying a container blank to an apparatus, a feeder device comprising: (a) a loader adapted to supply at least one blank; (b) a singulation mechanism operatively positioned relative to the loader for separating the at least one blank from the loader; (c) a transport mechanism in communication with the singulation mechanism and adapted to supply the at least one blank to the apparatus; and (d) a motion control assembly in communication with the singulation mechanism to selectively adjust positioning of the singulation mechanism between the loader and transport mechanism.
 2. The feeder device of claim 1, wherein the singulation mechanism includes a gripping assembly disposed on a conveyor.
 3. The feeder device of claim 2, wherein the gripping assembly is selectively driven in accordance with a predetermined velocity profile.
 4. The feeder device of claim 3, wherein the singulation mechanism includes a second gripping assembly disposed on a conveyor.
 5. The feeder device of claim 1, wherein the singulation mechanism includes a plurality of gripping assemblies extending between the loader and the transport mechanism.
 6. The feeder device of claim 5, wherein the plurality of gripping assemblies are selectively driven in accordance with a predetermined velocity profile.
 7. The feeder device of claim 6, wherein the plurality of gripping assemblies are vacuum operated.
 8. The feeder device of claim 1, wherein the transport mechanism includes a vacuum belt.
 9. In a container blank encapsulation apparatus of the type having an adhesive applicator, a feeder device comprising: (a) a loader adapted to continuously supply a plurality of container blanks; (b) a singulation mechanism operatively positional relative to the loader for separating at least one container blank from the plurality of container blanks; (c) a transport mechanism positioned to receive the at least one container blank adapted to supply the at least one container blank at a substantially constant web speed to the encapsulation apparatus; and (d) a motion control assembly in communication with the singulation mechanism to selectively adjust positioning of the singulation mechanism between the loader and transport mechanism.
 10. The feeder device of claim 9, wherein the motion control assembly selectively controls an operational aspect of the singulation mechanism, whereby the singulation mechanism supplies the at least one container blank to the transport mechanism as a function of the substantially constant web speed.
 11. The feeder device of claim 10, wherein the operational aspect is a velocity profile configured to reciprocate at least a portion of the singulation mechanism between a pick-up position and a release position.
 12. The feeder device of claim 10, wherein the singulation mechanism includes a gripping assembly disposed on a conveyor.
 13. The feeder device of claim 10, wherein the singulation assembly includes a plurality of gripping assemblies extending between the loader and the encapsulation apparatus.
 14. The feeder device of claim 13, wherein the operational aspect is a velocity profile configured to reciprocate the plurality of gripping assemblies of the singulation mechanism between a pick-up position and a release position.
 15. The feeder device of claim 14, wherein the plurality of gripping assemblies are vacuum operated.
 16. A feeder device for supplying a container blank to an apparatus, a feeder device comprising: (a) a loader adapted to supply at least one container blank; (b) a singulation mechanism operatively positioned relative to the loader for separating the at least one container blank from the loader; (c) a transport mechanism in communication with the singulation mechanism and adapted to supply the at least one container blank to the apparatus; and (d) a motion control assembly in communication with the singulation mechanism to selectively adjust positioning of the singulation mechanism between the loader and transport mechanism in accordance with a predetermined velocity profile.
 17. The feeder device of claim 16, wherein the predetermined velocity profile is a function of a web speed of the transport mechanism.
 18. The feeder device of claim 17, wherein the singulation mechanism includes at least one gripping assembly adapted for reciprocating motion between a pick-up position and a release position.
 19. The feeder device of claim 18, wherein the at least one gripping assembly is vacuum operated.
 20. The feeder device of claim 19, wherein the at least gripping assembly is coupled to a conveyor for reciprocating movement between the pick-up and release positions. 